Fuel cell

ABSTRACT

A fuel cell stack comprising a second metal separator set to have an external dimension larger than a first metal separator, wherein the second metal separator comprises, formed integrally, a first seal member in contact with the peripheral edge of a first electrolyte membrane/electrode structure, a second seal member in contact with the peripheral edge of the first metal separator, and a third seal member in contact with the peripheral edge of an adjoining fourth metal separator. Since the first seal member, the second seal member and the third seal member are integrally formed on one surface of the second separator or one surface of the first separator, a seal-forming step can be carried out at one effort, simply and economically. In addition, use of a triple seal structure containing the first through the third seal members can favorably improve the sealing feature of reaction gas and minimize reaction gas leakage.

RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 12/299,283, filed 31 Oct. 2008, which is a 35 U.S.C. 371 national stage filing of International Application No. PCT/JP2007/059311, filed 1 May 2007, which claims priority to Japanese Patent Application No. 2006-127578, filed 1 May 2006, Japanese Patent Application No. 2006-274165, filed 5 Oct. 2006, Japanese Patent Application No. 2006-333305, filed 11 Dec. 2006, and Japanese Patent Application No. 2007-030448, filed 9 Feb. 2007, all filed in Japan. This application is also related to Japanese Patent Application No. 2007-119308 filed 27 Apr. 2007. The contents of the aforementioned applications are hereby incorporated by reference.

TECHNICAL FIELD

The present invention relates to a fuel cell including an electrolyte electrode assembly and first and second separators sandwiching the electrolyte electrode assembly. The electrolyte electrode assembly includes electrodes and an electrolyte interposed between the electrodes.

BACKGROUND ART

For example, a solid polymer electrolyte fuel cell employs a solid polymer electrolyte membrane. The solid polymer electrolyte membrane is a polymer ion exchange membrane. In the fuel cell, the solid polymer electrolyte membrane is interposed between an anode and a cathode each comprising an electrode catalyst layer and porous carbon to form a membrane electrode assembly (electrolyte electrode assembly). The membrane electrode assembly is sandwiched between separators (bipolar plates) to form a unit cell. In use, normally, a predetermined number of unit cells are stacked together to form a fuel cell stack.

In general, the fuel cell adopts so called internal manifold structure where supply passages and discharge passages extend through the separators in the stacking direction. The fuel gas, the oxygen-containing gas, and the coolant are supplied from the respective supply passages to a fuel gas flow field, an oxygen-containing gas flow field, and a coolant flow field, and then, discharged to the respective discharge passages.

Therefore, in the fuel cell, it is necessary to prevent leakage of the fuel gas, the oxygen-containing gas, and the coolant individually. In this regard, for example, a fuel cell disclosed in Japanese Laid-Open Patent Publication No. 2002-270202 is known. In the fuel cell stack, as shown in FIG. 45, fuel cells 1001 are stacked together, and each of the fuel cells 1001 is formed by sandwiching an electrode assembly 1002 between a first separator 1003 and a second separator 1004.

The electrode assembly 1002 includes an anode 1002 b, a cathode 1002 c, and an electrolyte membrane 1002 a interposed between the anode 1002 b and the cathode 1002 c. The surface area of the cathode 1002 c is smaller than the surface area of the anode 1002 b. The first separator 1003 and the second separator 1004 are hermetically sealed by an outer seal member 1005 a, and a space between the second separator 1004 and the outer end of the electrode assembly 1002 are hermetically sealed by an inner seal member 1005 b. Further, a seal member 1005 c is provided between the fuel cells 1001.

As shown in FIG. 46, in the fuel cell 1001 disclosed in Japanese Laid-Open Patent Publication No. 2002-270202, a fuel gas inlet 1007 a, an oxygen-containing gas inlet 1008 a, and a coolant inlet 1009 a are formed at one end of first and second separators 1003, 1004 in a longitudinal direction, and a fuel gas outlet 1007 b, an oxygen-containing gas outlet 1008 b, and a coolant outlet 1009 b are formed at the other end of the first and second separators 1003, 1004 in the longitudinal direction.

In the fuel cell 1001, the dimensions of the first and second separators 1003, 1004 are relatively large in comparison with the outer dimensions of the electrode assembly 1002. In the case of adopting a structure where several hundreds of the fuel cells 1001 are stacked together and used as the fuel cell stack in a vehicle application, the overall size and weight of the fuel cell stack may become large undesirably.

Further, in the fuel cell 1001, an outer seal member 1005 and an inner seal member 1006 having desired shapes are formed beforehand, and then, the outer seal member 1005 and the inner seal member 1006 are supported, e.g., by the second separator 1004. Thus, the process of producing the fuel cell 1001 and operation of assembling the fuel cell 1001 may become complicated undesirably.

Further, in a fuel cell disclosed in Japanese Laid-Open Patent Publication No. 2002-025587, as shown in FIG. 47, a fuel unit cell 1101 is sandwiched between a first separator 1102 and a second separator 1103. The fuel unit cell 1101 is formed by sandwiching a solid polymer electrolyte membrane 1104 between a cathode 1105 and an anode 1106. The cathode 1105 and the anode 1106 include gas diffusion layers 1105 a, 1106 a.

The solid polymer electrolyte membrane 1104 protrudes out from inner circumferences of the cathode 1105 and the anode 1106. The surface area of the cathode 1105 is smaller than the surface area of the anode 1106.

A first seal 1107 a and a second seal 1107 b are attached between the first separator 1102 and the second separator 1103. The first seal 1107 a tightly contacts the solid polymer electrolyte membrane 1104, and the first seal 1107 a is provided around the cathode 1105. The second seal 1107 b is provided around the anode 1106, and around the first seal 1107 a. Thus, leakage of the oxygen-containing gas is prevented by the first seal 1107 a, and leakage of the fuel gas is prevented by the second seal 1107 b. In the structure, the first seal 1107 a and the second seal 1107 b are provided at positions deviated laterally with respect to the stacking direction of the fuel cell. Therefore, reduction in the overall thickness of the fuel cell in the stacking direction is achieved.

In the case of the fuel unit cell 1101, at the time of stacking a plurality of the fuel unit cells 1101, a coolant flow field is formed between each fuel unit cell 1101 along the electrode surface for cooling the fuel unit cell 1101. Thus, a seal member for preventing leakage of the coolant needs to be provided between each fuel unit cell 1101. In the presence of the seal member, the fuel unit cells 1101 tend to be spaced from each other, and reduction in the overall size of the fuel cell stack may not be achieved.

In a process control apparatus disclosed in Japanese Laid-Open Patent Publication No. 06-218275, as shown in FIG. 48, stack plates each formed by overlapping two plates in parallel with each other, and units 1202 are stacked alternately. The unit 1202 is formed by sandwiching an MEA 1202 a between an anode 1202 b and a cathode 1202 c, and sandwiching these components between a pair of contact plates 1202 d.

A first chamber 1203 a is formed between the plate 1201 a and the unit 1202, a second chamber 1203 b is formed between the plate 1201 b and the unit 1202, and a third chamber 1203 c is formed between the plates 1201 a, 1201 b. A passage 1205 extends through ends of the plates 1201 a, 1201 b through packings 1204.

The passage 1205 is connected to, e.g., the second chamber 1203 b through a flow field 1206 between the plates 1201 a, 1201 b. Though not shown, two other passages extend in the stacking direction, and the other two passages are connected to the first chamber 1203 a and the third chamber 1203 c, respectively through flow fields (not shown) between the plates 1201 a, 1201 b.

However, in the process control apparatus, the flow field 1206 for connecting the passage 1205 extending in the stacking direction to the second chamber 1203 b needs to have the sufficient flow field height in the stacking direction, and the sufficient seal height by the packing 1204, in order for sufficient fluid to flow therethrough. Thus, the space between the units 1202 becomes considerably large, and reduction in the overall size of the fuel cell cannot be achieved.

In particular, a fuel cell stack mounted in a vehicle is formed by stacking a large number of, e.g., several hundreds of fuel cells. Therefore, space between the fuel cells becomes large, and reduction in the overall size of the fuel cell cannot be achieved.

DISCLOSURE OF THE INVENTION

An object of the present invention is to provide a fuel cell which makes it possible to perform, in particular, seal forming operation economically and efficiently, while effectively improving the performance of preventing leakage of reactant gases.

Another object of the present invention is to provide a fuel cell which makes it possible to suitably reduce the overall weight and size of the fuel cell, in particular, even if a larger number of components are stacked to form the fuel cell.

Still another object of the present invention is to provide a fuel cell which makes it possible to simplify the structure of the fuel cell, and, in particular, economically and efficiently perform seal forming operation.

Still another object of the present invention is to provide a fuel cell which makes it possible to suitably prevent leakage of a fuel gas, an oxygen-containing gas, and a coolant, and reduce the thickness in the stacking direction as much as possible.

Still another object of the present invention is to provide a fuel cell in which reactant gases suitably flow between reactant gas passages extending in the stacking direction and reactant gas flow fields extending along the electrode surfaces, and which makes it possible to reduce the thickness in the stacking direction.

The present invention relates to a fuel cell including an electrolyte electrode assembly and first and second separators sandwiching the electrolyte electrode assembly. The electrolyte electrode assembly includes a first electrode, a second electrode, and an electrolyte interposed between the first electrode and the second electrode. The second electrode has a surface area smaller than that of the first electrode.

The first separator faces the first electrode, the second separator has outer dimensions different from those of the first separator, and faces the second electrode. A first seal member, a second seal member, and a third seal member are formed integrally on one surface of the second separator or on one surface of the first separator. The first seal member contacts the electrolyte at an outer end of the electrolyte electrode assembly. The second seal member contacts an outer end of the first separator or the second separator. A third seal member contacts an outer end of the adjacent second separator or an outer end of the adjacent first separator.

Further, in a fuel cell according to the present invention, outer dimensions of the first separator are smaller than those of the second separator, and fluid passages at least including a fuel gas supply passage, a fuel gas discharge passage, an oxygen-containing gas supply passage, an oxygen-containing gas discharge passage extend through an outer end of the second separator in the stacking direction, at positions outside the outer end of the first separator.

Further, in a fuel cell according to the present invention, outer dimensions of the second metal separator are larger than those of the first metal separator, metal of the first metal separator is exposed over the entire surface, and a seal member is formed integrally only on the second metal separator.

The seal member is formed on one surface of the second metal separator facing the electrode. The seal member includes an inner seal contacting an outer end of the electrolyte electrode assembly, and an outer seal contacting an outer end of the adjacent second metal member.

Further, in a fuel cell according to the present invention, at least the first separator or the second separator includes a first seal for preventing leakage of the fuel gas, a second seal for preventing leakage of the oxygen-containing gas, and a third seal for preventing leakage of the coolant. The first seal, the second seal, and the third seal are offset from one another in the stacking direction.

Further, in a fuel cell according to the present invention, the electrolyte electrode assembly has an uneven portion in the same plane as the electrode surface, and the uneven portion forms a connection channel connecting the reactant gas flow field to the reactant gas passage. Uneven portions of adjacent electrolyte electrode assemblies in the stacking direction are offset from each other in the stacking direction.

Further, in a fuel cell according to the present invention, the first electrolyte electrode assembly has a first uneven portion in the same plane as the electrode surface, and the first uneven portion forms a first connection channel connecting the reactant gas flow field for supplying the reactant gas along the electrode surface, to the reactant gas passage. The second electrolyte electrode assembly has a second uneven portion in the same plane as the electrode surface, and the second uneven portion forms a second connection channel connecting the reactant gas flow field for supplying the reactant gas along the electrode surface, to the reactant gas passage. The first uneven portion and the second uneven portion are offset from each other in the stacking direction.

In the present invention, the first seal member, the second seal member, and the third seal member are formed integrally on one surface of the second separator or on one surface of the second separator. Thus, the seal forming process is significantly simplified, and carried out economically. Further, by adopting triple seal structure including the first to third seal members, improvement in the reactant gas sealing performance is achieved suitably, and leakage of the reactant gas is prevented as much as possible.

Further, the outer dimensions of one of the first separator and the second separator are relatively small in comparison with the outer dimensions of the other of the first separator and the second separator. Thus, the desired rigidity at the time of stacking the fuel cells, and the rigidity of the electrode surface required for assembling the fuel cells are maintained. Further, the weight reduction of the fuel cell is achieved, and the overall weight of the fuel cell stack is reduced.

Further, in the present invention, the outer dimensions of the first separator are smaller than the outer dimensions of the second separator. The fluid passages pass through only the second separator. Thus, the size of the first separator is reduced as much as possible, and weight reduction is achieved easily. Therefore, in particular, at the time of stacking a large number of fuel cells to form a fuel cell stack, the overall size and weight of the fuel cell stack are reduced considerably.

Further, in the present invention, the seal members are formed integrally with the second metal separator. Thus, sealing structure is simplified significantly. In comparison with the structure in which the seal members having a desired shape are formed beforehand, the performance of assembling the fuel cell is improved suitably. It is because operation of positioning the seal members relative to the second metal separator is not required at the time of assembling the fuel cell.

Further, operation of forming the seal members is not required for the first metal separator, and operation of forming the seal members is only required for the second metal separator. Thus, seal forming operation is performed economically and efficiently. Reduction in the overall cost of producing the fuel cell is achieved easily.

Further, in the present invention, the first seal for preventing leakage of the fuel gas, the second seal for preventing leakage of the oxygen-containing gas, and the third seal for preventing leakage of the coolant are not overlapped with each other in the stacking direction. Thus, the sufficient seal height is achieved in each of the first seal, the second seal, and the third seal, and it is possible to suitably prevent leakage of the fuel gas, the oxygen-containing gas, and the coolant, and reduce the thickness in the stacking direction. Accordingly, the overall size of the fuel cell is reduced easily and reliably.

Further, in the present invention, the uneven portions provided in the electrolyte electrode assemblies adjacent to each other in the stacking direction are offset from each other in the stacking direction. Therefore, the adjacent channels are not overlapped with each other in the stacking direction. Thus, it is possible to reduce the thickness in the stacking direction in each unit cell, while maintaining the sufficient flow field height and seal height in the channel connecting the reactant gas flow field and the reactant gas passages. Accordingly, the overall size of the fuel cell is reduced easily, and in particular, the size of the fuel cell stack mounted in the vehicle is reduced suitably.

Further, in the present invention, the first electrolyte electrode assembly and the second electrolyte electrode assembly are adjacent to each other in the stacking direction, and the first uneven portion of the first electrolyte electrode assembly and the second uneven portion of the second electrolyte electrode assembly are offset from each other in the stacking direction. Therefore, the adjacent first channel and second channel are not overlapped with each other in the stacking direction. Thus, it is possible to reduce the thickness of the first unit cell and the second unit cell in the stacking direction while maintaining the sufficient flow field height and seal height in the first channel and the second channel connecting the reactant gas flow field to the reactant gas passages. Accordingly, the overall size of the fuel cell is reduced easily, and in particular, the size of the fuel cell stack mounted in the vehicle is reduced suitably.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic perspective view showing a fuel cell according to a first embodiment of the present invention.

FIG. 2 is a cross sectional view showing the fuel cell.

FIG. 3 is an exploded perspective view showing unit cells of the fuel cell.

FIG. 4 is a view showing one surface of a first metal separator.

FIG. 5 is a view showing one surface of a second metal separator.

FIG. 6 is a view showing the other surface of the second metal separator.

FIG. 7 is a view showing one surface of a fourth metal separator.

FIG. 8 is a view showing the other surface of the fourth metal separator.

FIG. 9 is a view showing a flow of an oxygen-containing gas in the fuel cell.

FIG. 10 is a view showing another flow of the oxygen-containing gas in the fuel cell.

FIG. 11 is a view showing a flow of a fuel gas in the fuel cell.

FIG. 12 is a view showing another flow of the fuel gas in the fuel cell.

FIG. 13 is a view showing a flow of a coolant in the fuel cell.

FIG. 14 is a view showing another flow of the coolant in the fuel cell.

FIG. 15 is a partial cross sectional view showing a fuel cell according to a second embodiment of the present invention.

FIG. 16 is a partial cross sectional view showing a fuel cell according to a third embodiment of the present invention.

FIG. 17 is a cross sectional view showing a fuel cell according to a fourth embodiment of the present invention.

FIG. 18 is an exploded perspective view showing the fuel cell.

FIG. 19 is a view showing one surface of a second metal separator of the fuel cell.

FIG. 20 is a cross sectional view showing a fuel cell according to a fifth embodiment of the present invention.

FIG. 21 is a cross sectional view showing a fuel cell according to a sixth embodiment of the present invention.

FIG. 22 is an exploded perspective view showing the fuel cell.

FIG. 23 is a view showing one surface of a first metal separator of the fuel cell.

FIG. 24 is a view showing the other surface of the first metal separator.

FIG. 25 is a view showing one surface of a second metal separator of the fuel cell.

FIG. 26 is a cross sectional view showing a fuel cell according to a seventh embodiment of the present invention.

FIG. 27 is a cross sectional view showing a fuel cell according to an eighth embodiment of the present invention.

FIG. 28 is an exploded perspective view showing a fuel cell according to a ninth embodiment of the present invention.

FIG. 29 is an exploded perspective view showing a fuel cell according to a tenth embodiment of the present invention.

FIG. 30 is an exploded perspective view showing a fuel cell according to an eleventh embodiment of the present invention.

FIG. 31 is a cross sectional view showing a fuel cell according to a twelfth embodiment of the present invention.

FIG. 32 is an exploded perspective view showing a unit cell of the fuel cell.

FIG. 33 is a view showing one surface of a second metal separator of the unit cell.

FIG. 34 is a cross sectional view showing a fuel cell according to a thirteenth embodiment of the present invention.

FIG. 35 is an exploded perspective view showing a unit cell of the fuel cell.

FIG. 36 is a front view showing a first metal separator of the unit cell.

FIG. 37 is a view showing one surface of a second metal separator of the unit cell.

FIG. 38 is a cross sectional view showing a fuel cell according to a fourteenth embodiment of the present invention.

FIG. 39 is an exploded perspective view showing a unit cell of the fuel cell.

FIG. 40 is a cross sectional view showing a fuel cell according to a fifteenth embodiment of the present invention.

FIG. 41 is an exploded perspective view showing a unit cell of the fuel cell.

FIG. 42 is a cross sectional view showing a fuel cell according to a sixteenth embodiment of the present invention.

FIG. 43 is an exploded perspective view showing a unit cell of the fuel cell.

FIG. 44 is a cross sectional view showing a fuel cell stack according to a seventeenth embodiment of the present invention.

FIG. 45 is a view showing a conventional fuel cell stack.

FIG. 46 is a view showing the fuel cell.

FIG. 47 is a view showing a conventional fuel cell.

FIG. 48 is a view showing a conventional process control apparatus.

BEST MODE FOR CARRYING OUT THE INVENTION

FIG. 1 is a perspective view schematically showing a fuel cell 10 according to a first embodiment of the present invention. FIG. 2 is a cross sectional view showing the fuel cell 10.

The fuel cell 10 includes a stack body 14 formed by stacking unit cells 12 a, 12 b alternately in a horizontal direction indicated by an arrow A. End plates 16 a, 16 b are provided at opposite ends of the stack body 14 in the stacking direction. Though components between the end plates 16 a, 16 b are tightened together by tie-rods (not shown) in the embodiment, for example, the entire stack body 14 may be placed in a casing (not shown).

The unit cell 12 a is formed by sandwiching a first membrane electrode assembly (electrolyte electrode assembly) 20 a between a first metal separator 22 and a second metal separator 24. The unit cell 12 b is formed by sandwiching a second membrane electrode assembly 20 b between a third metal separator 26 and a fourth metal separator 28. The unit cells 12 a, 12 b are oppositely oriented to each other at an angle of 180° on a plane of the unit cells 12 a, 12 b. In practice, the second membrane electrode assembly 20 b is the same as the first membrane electrode assembly 20 a, the third metal separator 26 is the same as the first metal separator 22, and the fourth metal separator 28 is the same as the second metal separator 24.

As shown in FIG. 3, the first membrane electrode assembly 20 a comprises a cathode (first electrode) 32 a, an anode (second electrode) 34 a, and a solid polymer electrolyte membrane (electrolyte) 30 a interposed between the cathode 32 a and the anode 34 a. The solid polymer electrolyte membrane 30 a is formed by impregnating a thin membrane of perfluorosulfonic acid with water, for example. The surface area of the cathode 32 a is larger than the surface area of the anode 34 a. The cathode 32 a is provided over the entire surface of the solid polymer electrolyte membrane 30 a (referred to as a stepped MEA).

Each of the cathode 32 a and the anode 34 a has a gas diffusion layer (not shown) such as a carbon paper, and an electrode catalyst layer (not shown) of platinum alloy supported on surfaces of porous carbon particles. The carbon particles are deposited uniformly on the surface of the gas diffusion layer. Each of the cathode 32 a and the anode 34 has an area (catalyst area) 36 a for applying a catalyst.

The first membrane electrode assembly 20 a has a substantially quadrangular shape as a whole. At opposite ends of the first membrane electrode assembly 20 a in the direction indicated by the arrow B, first uneven portions 38 a are provided in the same plane as the electrode surface. The first uneven portion 38 a at one end of the first membrane electrode assembly 20 a in the direction indicated by the arrow B includes a first extension 37 a, a first cutout 39 a, a second extension 37 b, and a second cutout 39 b from upper to lower positions. Further, the first uneven portion 38 a at the other end of the first membrane electrode assembly 20 a in the direction indicated by the arrow B includes a third extension 37 c, a third cutout 39 c, a fourth extension 37 d, and a fourth cutout 39 d from upper to lower positions.

The outer dimensions of the first metal separator 22 are smaller than the outer dimensions of the second metal separator 24. As shown in FIGS. 3 and 4, the first metal separator 22 has a first oxygen-containing gas flow field (first reactant gas flow field) 40 on a surface 22 a facing the first membrane electrode assembly 20 a. The first oxygen-containing gas flow field (first reactant gas flow field) 40 is formed in an area corresponding to the catalyst area 36 a of the first membrane electrode assembly 20 a. By forming ridges 40 a protruding on the side of the surface 22 a and grooves 40 b alternately, the first oxygen-containing gas flow field 40 extends straight in the direction indicated by the arrow B. Embossed sections 40 c are formed on both sides of the first oxygen-containing gas flow field 40. At one end of the first oxygen-containing gas flow field 40 in the direction indicated by the arrow B, a corrugated inlet section 41 a is formed, and likewise, at the other end of the first oxygen-containing gas flow field 40, a corrugated outlet section 41 b is formed. As shown in FIG. 4, the inlet section 41 a and the outlet section 41 b protrude from the outer end of the first membrane electrode assembly 20 a, respectively.

The first metal separator 22 has an outer shape forming section 42 having a desired uneven shape. The outer shape forming section 42 is larger than the outer size of the first membrane electrode assembly 20 a. By forming the first oxygen-containing gas flow field 40 on the surface 22 a of the first metal separator 22, a first coolant flow field 44 is formed on the back of the corrugated surface 22 a.

As shown in FIG. 3, the second metal separator 24 has a laterally elongated rectangular shape. At one end of the second metal separator 24 and the fourth metal separator 28 in the direction indicated by the arrow B, an oxygen-containing gas supply passage 46 a for supplying an oxygen-containing gas (one reactant gas), a coolant supply passage 48 a for supplying a coolant, and a fuel gas discharge passage 50 b for discharging a fuel gas (other reactant gas), such as a hydrogen-containing gas, are arranged vertically in a direction indicated by an arrow C. The oxygen-containing gas supply passage 46 a, the coolant supply passage 48 a, and the fuel gas discharge passage 50 b extend through the second metal separator 24 and the fourth metal separator 28 in the direction indicated by the arrow A.

At the other end of the second metal separator 24 and the fourth metal separator 28 in the direction indicated by the arrow B, a fuel gas supply passage 50 a for supplying the fuel gas, a coolant discharge passage 48 b for discharging the coolant, and an oxygen-containing gas discharge passage 46 b for discharging the oxygen-containing gas are arranged vertically in the direction indicated by the arrow C. The fuel gas supply passage 50 a, the coolant discharge passage 48 b, and the oxygen-containing gas discharge passage 46 b extend through the second metal separator 24 and the fourth metal separator 28 in the direction indicated by the arrow A.

As shown in FIG. 5, the second metal separator 24 has a first fuel gas flow field (second reactant gas flow field) 52 on a surface 24 a facing the first membrane electrode assembly 20 a. The first fuel gas flow field 52 is formed in an area corresponding to the catalyst area 36 a of the first membrane electrode assembly 20 a. By forming ridges 52 a protruding on the side of the surface 24 a and grooves 52 b alternately, the first fuel gas flow field 52 extends in the direction indicated by the arrow B. Embossed sections 52 c are formed on both sides of the first fuel gas flow field 52.

As shown in FIG. 6, the second metal separator 24 has a second coolant flow field 54 on a surface 24 b, i.e., on the back of the surface 24 a forming the first fuel gas flow field 52. At one end of the second coolant flow field 54 in the direction indicated by the arrow B, a corrugated inlet section 56 a is formed, and likewise, at the other end of the second coolant flow field 54 in the direction indicated by the arrow B, a corrugated outlet section 56 b is formed.

When the second metal separator 24 and the third metal separator 26 are stacked together, the inlet section 56 a and the outlet section 56 b are provided at cutouts of the third metal separator 26. The coolant supply passage 48 a is connected to the second coolant flow field 54 through the inlet section 56 a and the coolant discharge passage 48 b is connected to the second coolant flow field 54 through the outlet section 56 b.

The second metal separator 24 has two fuel gas inlet holes 58 a adjacent to the fuel gas supply passage 50 a, and two fuel gas outlet holes 58 b adjacent to the fuel gas discharge passage 50 b. Further, the second metal separator 24 has three oxygen-containing gas inlet holes 60 a near the oxygen-containing gas supply passage 46 a, and three oxygen-containing gas outlet holes 60 b near the oxygen-containing gas discharge passage 46 b.

As shown in FIGS. 2 and 5, a seal member 62 is formed integrally on a surface 24 a of the second metal separator 24, around the first fuel gas flow field 52. The seal member 62 includes a first seal (first seal member) 62 a as an inner seal formed integrally with the second metal separator 24, a second seal (second seal member) 62 b positioned outside the first seal 62 a, and a third seal (third seal member) 62 c as an outer seal positioned outside the second seal 62 b. The seal member 62 is made of an EPDM (Etylene Propylene rubber), a silicone rubber, a nitrile rubber, or an acrylic rubber. For example, the seal member 62 is formed by injection molding using melted resin obtained by heating silicone resin to a predetermined temperature (e.g., 160° C. to 170° C.).

The first seal member 62 a contacts the outer end of the first membrane electrode assembly 20 a, i.e., the outer end of the solid polymer electrolyte membrane 30 a. The second seal member 62 b contacts the outer end of the first metal separator 22. The third seal member 62 c contacts the fourth metal separator 28 corresponding to the second metal separator of the adjacent unit cell 12 b.

The first seal member 62 a forms an inner seal member for preventing leakage of the fuel gas, the second seal member 62 b forms an intermediate seal member for preventing leakage of the oxygen-containing gas, and the third seal member 62 c forms an outer seal member for preventing leakage of the coolant.

The second membrane electrode assembly 20 b has the same structure as the first membrane electrode assembly 20 a. At opposite ends of the second membrane electrode assembly 20 b in the direction indicated by the arrow B, second uneven portions 38 b are provided in the same plane as the electrode surface. The second uneven portion 38 b at one end of the second membrane electrode assembly 20 b in the direction indicated by the arrow B includes a fifth cutout 39 e, a fifth extension 37 e, a sixth cutout 39 f, and a sixth extension 37 f from upper to lower positions. Further, the second uneven portion at the other end of the second membrane electrode assembly 20 b in the direction indicated by the arrow B includes a seventh cutout 39 g, a seventh extension 37 g, an eighth cutout 39 h, and an eighth extension 37 h from upper to lower positions.

The third metal separator 26 has a second oxygen-containing gas flow field 64 on a surface 26 a facing the second membrane electrode assembly 20 b. At one end of the second oxygen-containing gas flow field 64 in the direction indicated by the arrow B, a corrugated inlet section 63 a is formed, and likewise, at the other end of the second oxygen-containing gas flow field 64 in the direction indicated by the arrow B, a corrugated outlet section 63 b is formed. The inlet section 63 a and the outlet section 63 b protrude from the outer ends of the second membrane electrode assembly 20 b, respectively. Thus, when the surface 26 b of the third metal separator 26 is stacked on the surface 24 b of the second metal separator 24, the second coolant flow field 54 is formed between the second metal separator 24 and the third metal separator 26. The third metal separator 26 has an outer shape forming portion 65 having a predetermined uneven shape.

As shown in FIG. 7, the fourth metal separator 28 has a second fuel gas flow field 66 on a surface 28 a facing the second membrane electrode assembly 20 b. The second fuel gas flow field 66 includes ridges 66 a and grooves 66 b, extending in the direction indicated by the arrow B. At opposite ends of the second fuel gas flow field 66, embossed sections 66 c are formed.

As shown in FIG. 8, the first coolant flow field 44 is formed on a surface 28 b of the fourth metal separator 28, i.e., on the back of the surface 28 a forming the second fuel gas flow field 66. When the fourth metal separator 28 is stacked on the first metal separator 22, the first coolant flow field 44 is formed between the first metal separator 22 and the fourth metal separator 28. At opposite ends of the first coolant flow field 44 in the direction indicated by the arrow B, a corrugated inlet section 68 a and a corrugated outlet section 68 b are provided at outer positions.

The inlet section 68 a and the outlet section 68 b connect the coolant supply passage 48 a and the coolant discharge passage 48 b to the first coolant flow field 44 through cutouts of the first metal separator 22.

The fourth metal separator 28 has two inlet holes 70 a and two outlet holes 70 b at positions deviated from the two inlet holes 58 a and the two outlet holes 58 b of the second metal separator 24 in the stacking direction. Further, the fourth metal separator 28 has three inlet holes 72 a and three outlet holes 72 b at positions deviated from the three inlet holes 60 a and the three outlet holes 60 b in the stacking direction.

As shown in FIG. 7, a seal member 74 is formed integrally on a surface 28 a of the fourth metal separator 28, around the second fuel gas flow field 66. The seal member 74 includes a first seal (first seal member) 74 a as an inner seal, a second seal (second seal member) 74 b as an intermediate seal positioned outside the first seal 74 a, and a third seal (third seal member) 74 c as an outer seal positioned outside the second seal 74 b. The first seal 74 a as the inner seal for preventing leakage of the fuel gas contacts the outer end of the solid polymer electrolyte membrane 30 b of the second membrane electrode assembly 20 b, the second seal 74 b as the intermediate seal for preventing leakage of the oxygen-containing gas contacts the outer end of the third metal separator 26, and the third seal 74 c as the outer seal for preventing leakage of the coolant contacts the outer end of the second metal separator 24 of the unit cell 12 a.

As shown in FIGS. 9 and 10, the second metal separator 24 and the fourth metal separator 28 include a channel 75 connecting the oxygen-containing gas supply passage 46 a to the first oxygen-containing gas flow field 40 and the second oxygen-containing gas flow field 64 in the presence of the third seals 62 c, 74 c. The channel 75 includes inlet holes (through holes) 60 a, 72 a for the oxygen-containing gas. Likewise, as shown in FIGS. 11 and 12, the second metal separator 24 and the fourth metal separator 28 include a channel 77 connecting the fuel gas supply passage 50 a to the first fuel gas flow field 52 and the second fuel gas flow field 66 in the presence of the third seals 62 c, 74 c. The channel 77 includes inlet holes (through holes) 58 a, 70 a for the fuel gas.

A first channel 76 a is formed in the unit cell 12 a by the first uneven portion 38 a, and a second channel 76 b is formed in the unit cell 12 b by the second uneven portion 38 b.

As shown in FIG. 9, the first channel 76 a is formed at the first cutout 39 a between the first metal separator 22 and the second metal separator 24. The first channel 76 a includes a first oxygen-containing gas supply connection channel 78 a connecting the oxygen-containing gas supply passage 46 a to the first oxygen-containing gas flow field 40. As shown in FIG. 11, the first channel 76 a includes a first fuel gas supply connection channel 79 a formed between the third extension 37 c and the second metal separator 24 for connecting the fuel gas supply passage 50 a to the first fuel gas flow field 52.

As shown in FIG. 3, the first channel 76 a includes a first oxygen-containing gas discharge connection channel 78 b formed at the fourth cutout 39 d between the first metal separator 22 and the second metal separator 24 for connecting the oxygen-containing gas discharge passage 46 b to the first oxygen-containing gas flow field 40. The first channel 76 a includes a first fuel gas discharge connection channel 79 b formed between the second extension 37 b and the second metal separator 24 for connecting the fuel gas supply passage 50 a to the first fuel gas flow field 52.

As shown in FIG. 10, the second channel 76 b includes a second oxygen-containing gas supply connection channel 78 c formed at the fifth cutout 39 e between the third metal separator 26 and the fourth metal separator 28 for connecting the oxygen-containing gas supply passage 46 a to the second oxygen-containing gas flow field 64. As shown in FIG. 12, the second channel 76 b includes a second fuel gas supply connection channel 79 c formed between the seventh extension 37 g and the fourth metal separator 28 for connecting the fuel gas supply passage 50 a to the second fuel gas flow field 66.

As shown in FIG. 3, the second channel 76 b includes a second oxygen-containing gas discharge connection channel 78 d formed at the eighth cutout 39 h between the third metal separator 26 and the fourth metal separator 28 for connecting the oxygen-containing gas discharge passage 46 b to the second oxygen-containing gas flow field 64. The second channel 76 b includes a second fuel gas discharge connection channel 79 d formed between the sixth extension 37 f and the fourth metal separator 28 for connecting the fuel gas supply passage 50 a to the second fuel gas flow field 66.

Operation of the fuel cell 10 having the above structure will be described below.

As shown in FIG. 1, at the end plate 16 a, an oxygen-containing gas is supplied to the oxygen-containing gas supply passage 46 a, and a fuel gas such as a hydrogen-containing gas is supplied to the fuel gas supply passage 50 a. Further, a coolant such as pure water or ethylene glycol is supplied to the coolant supply passage 48 a.

As shown in FIG. 6, the second metal separator 24 of the unit cell 12 a has the three inlet holes 60 a connected to the oxygen-containing gas supply passage 46 a from the surface 24 b. Further, as shown in FIG. 8, the fourth metal separator 28 of the unit cell 12 b has the three inlet holes 72 a connected to the oxygen-containing gas supply passage 46 a from the surface 28 b.

In the structure, as shown in FIG. 9, some of the oxygen-containing gas supplied to the oxygen-containing gas supply passage 46 a flows through the inlet holes 60 a of the second metal separator 24 to the first oxygen-containing gas supply connection channel 78 a on the surface 24 a, and the oxygen-containing gas flows into the first oxygen-containing gas flow field 40 from the inlet section 41 a of the first metal separator 22.

As shown in FIG. 10, in the unit cell 12 b, some of the oxygen-containing gas supplied to the oxygen-containing gas supply passage 46 a flows through the inlet holes 72 a of the fourth metal separator 28 to the second oxygen-containing gas supply connection channel 78 c on the surface 28 a, and the oxygen-containing gas flows into the second oxygen-containing gas flow field 64 from the inlet section 63 a of the third metal separator 26.

Further, as shown in FIG. 6, the second metal separator 24 has two inlet holes 58 a connected to the fuel gas supply passage 50 a on the surface 24 b. As shown in FIG. 8, the fourth metal separator 28 has two inlet holes 70 a connected to the fuel gas supply passage 50 a on the surface 28 b.

Thus, as shown in FIG. 11, some of the fuel gas supplied to the fuel gas supply passage 50 a flows through the inlet holes 58 a of the second metal separator 24 to the first fuel gas supply connection channel 79 a on the surface 24 a, and the fuel gas is supplied to the first fuel gas flow field 52 connected to the first fuel gas supply connection channel 79 a.

Further, as shown in FIG. 12, some of the fuel gas supplied to the fuel gas supply passage 50 a flows through the inlet holes 70 a of the fourth metal separator 28 to the second fuel gas supply connection channel 79 c on the surface 28 a, and the fuel gas is supplied to the second fuel gas flow field 66 connected to the second fuel gas supply connection channel 79 c.

Thus, as shown in FIG. 3, in the first membrane electrode assembly 20 a, the oxygen-containing gas supplied to the cathode 32 a and the fuel gas supplied to the anode 34 a are consumed in the electrochemical reactions at electrode catalyst layers for generating electricity. Similarly, in the second membrane electrode assembly 20 b, the oxygen-containing gas supplied to the cathode 32 b and the fuel gas supplied to the anode 34 b are consumed for generating electricity.

The oxygen-containing gas from the first oxygen-containing gas flow field 40 of the unit cell 12 a flows from the outlet section 41 b to the first oxygen-containing gas discharge connection channel 78 b, and flows to the surface 24 b through the outlet holes 60 b of the second metal separator 24. Then, the oxygen-containing gas is discharged to the oxygen-containing gas discharge passage 46 b. Likewise, the oxygen-containing gas from the second oxygen-containing gas flow field 64 of the unit cell 12 b flows from the outlet section 63 b to the second oxygen-containing gas discharge connection channel 78 d. Then, the oxygen-containing gas is discharged to the oxygen-containing gas discharge passage 46 b through the outlet holes 72 b of the fourth metal separator 28.

Further, the fuel gas from the first fuel gas flow field 52 of the second metal separator 24 flows into the first fuel gas discharge connection channel 79 b, and flows toward the surface 24 b through the outlet holes 58 b. Then, the fuel gas is discharged to the fuel gas discharge passage 50 b. Likewise, the fuel gas from the second fuel gas flow field 66 of the fourth metal separator 28 flows into the second fuel gas discharge connection channel 79 d, and flows toward the surface 28 b through the outlet holes 70 b. Then, the fuel gas is discharged to the fuel gas discharge passage 50 b.

Further, as shown in FIG. 8, the inlet section 68 a and the outlet section 68 b connected to the first coolant flow field 44 are provided on the surface 28 b of the fourth metal separator 28. The inlet section 68 a and the outlet section 68 b are provided at positions corresponding to the cutouts of the first metal separator 22.

In the structure, as shown in FIG. 13, the coolant supplied to the coolant supply passage 48 a flows from the surface 28 b of the fourth metal separator 28 to the first coolant flow field 44 formed between the fourth metal separator 28 and the first metal separator 22 through the inlet section 68 a. After the coolant flows through the first coolant flow field 44 for cooling the fuel cell 10, the coolant is discharged from the surface 28 b to the coolant discharge passage 48 b through the outlet section 68 b (see FIG. 3).

As shown in FIG. 6, the inlet section 56 a and the outlet section 56 b connected to the second coolant flow field 54 are provided on the surface 24 b of the second metal separator 24. The inlet section 56 a and the outlet section 56 b are provided at positions corresponding to the cutouts of the third metal separator 26.

Thus, as shown in FIG. 14, the coolant supplied to the coolant supply passage 48 a flows from the surface 24 b to the second coolant flow field 54 formed between the second metal separator 24 and the third metal separator 26 through the inlet section 56 a. After the coolant flows through the second coolant flow field 54, the coolant is discharged through the outlet section 56 b from the surface 24 b into the coolant discharge passage 48 b (see FIG. 3).

In the first embodiment, the outer dimensions of the first metal separator 22 of the unit cell 12 a are smaller than the outer dimensions of the second metal separator 24. In the first membrane electrode assembly 20 a, the surface area of the anode 34 a is smaller than the surface area of the cathode 32 a.

As shown in FIGS. 2 and 5, the first seal member 62 a which contacts the outer end of the solid polymer electrolyte membrane 30 a of the first membrane electrode assembly 20 a, the second seal member 62 b which contacts the outer end of the second metal separator 24, and the third seal member 62 c which contacts the fourth metal separator 28 (substantially the same as the second metal separator 24) of the adjacent unit cell 12 b are formed integrally on the surface 24 a of the second metal separator 24.

Thus, in the second metal separator 24, simply by forming the seal only on the surface 24 a, in comparison with the case where the seal is formed also on the surface 24 b, the seal forming process is significantly simplified, and carried out economically.

The first seal 62 a for preventing leakage of the fuel gas, the second seal 62 b for preventing leakage of the oxygen-containing gas, and the third seal 62 c for preventing leakage of the coolant are offset from one another in the stacking direction indicated by the arrow A. Thus, in comparison with the structure in which at least any two of the fuel gas seal, the oxygen-containing gas seal, and the coolant seal are overlapped with each other, reduction in the thickness of the fuel cell 10 is achieved easily.

In the structure, each of the first seal 62 a, the second seal 62 b, and the third seal 62 c has the sufficient height for suitably preventing leakage of the oxygen-containing gas, the fuel gas, and the coolant. Reduction in the thickness in the stacking direction is achieved. The overall size of the fuel cell 10 is reduced easily and reliably.

Further, the fuel gas flow field 52, the inlet holes 58 a, and the outlet holes 58 b are sealed by triple seal structure including the first seal member 62 a, the second seal member 62 b, and the third seal member 62 c. Thus, improvement in the fuel gas sealing performance is achieved suitably, and leakage of the fuel gas is prevented as much as possible.

Further, in the first embodiment, the oxygen-containing gas supply passage 46 a, the coolant supply passage 48 a, the fuel gas discharge passage 50 b, the fuel gas supply passage 50 a, the coolant discharge passage 48 b, and the oxygen-containing gas discharge passage 46 b are not provided in the first metal separator 22. In the structure, a desired rigidity at the time of stacking the unit cells 12, and the rigidity of the electrode surface required for assembling the unit cells 12 a is maintained. Further, the weight reduction of the unit cell 12 a is achieved, and the overall weight of the fuel cell 10 is reduced easily. Also in the unit cell 12 b, the same advantages as in the case of the unit cell 12 a are achieved.

In the structure, the overall weight and size of the fuel cell 10 are reduced easily. In particular, at the time of stacking a large number of unit cells 12 a, 12 b together to form the fuel cell 10 mounted in a vehicle, the overall weight of the fuel cell 10 is reduced significantly, and improvement in the fuel economy is achieved reliably.

Further, in the unit cell 12 b, in effect, the first metal separator 22 can be used as the third metal separator 26 by 180° rotation such that the first metal separator 22 and the third metal separator 26 are oriented oppositely. The second metal separator 24 can be used as the fourth metal separator 28 by 180° rotation such that the second metal separator 24 and the fourth metal separator 28 are oriented oppositely. Thus, the fuel cell 10 has economical structure as a whole.

The first seal member 62 a, the second seal member 62 b, and the third seal member 62 c are provided on the second metal separator 24. The rounded front ends of the first seal member 62 a, the second seal member 62 b, and the third seal member 62 c contact the flat outer end of the solid polymer electrolyte membrane 30 a, the surface 22 a of the first metal separator 22, and the surface 28 b of the fourth metal separator 28, respectively. In the structure, it is possible to reliably prevent decrease in the line pressure in the sealing regions, occurrence of leakage, and deformation of the separators.

In the first embodiment, the seal member 62 is formed integrally with the second metal separator 24. In the structure, unlike the structure in which the seal member 62 having a desired shape is formed beforehand, and then, the seal member 62 is joined to the second metal separator 24, operation of positioning the seal member 62 relative to the second metal separator 24 is not required. Thus, the sealing structure is simplified significantly, and performance in the operation of assembling the fuel cell 10 is improved suitably.

As shown in FIGS. 2 and 5, the first seal 62 a which contacts the outer end of the solid polymer electrolyte membrane 30 a of the first membrane electrode assembly 20 a, the second seal 62 b which contacts the outer end of the second metal separator 24, and the third seal 62 c which contacts the fourth metal separator 28 (substantially the same as the second metal separator 24) of the adjacent unit cell 12 b are formed integrally on the surface 24 a of the second metal separator 24.

Thus, in the second metal separator 24, simply by forming the seal only on the surface 24 a, in comparison with the case where the seal is formed also on the surface 24 b, the seal forming process is significantly simplified, and carried out economically.

Further, in the first metal separator 22, no seal forming operation is required. Thus, it is sufficient to form the seal member 62 only on the second metal separator 24. The seal forming operation is performed simply and economically. The overall production cost of the fuel cell 10 is reduced easily.

Further, in the first embodiment, the first uneven portions 38 a of the first membrane electrode assembly 20 a and the second uneven portions 38 b of the second membrane electrode assembly 20 b which are adjacent to each other in the stacking direction are offset from each other in the stacking direction. In the structure, the adjacent first channel 76 a and the second channel 76 b are not overlapped with each other in the stacking direction.

Specifically, for example, the first oxygen-containing gas supply connection channel 78 a connecting the first oxygen-containing gas flow field 40 to the oxygen-containing gas supply passage 46 a is offset from the second oxygen-containing gas supply connection channel 78 c connecting the second oxygen-containing gas flow field 64 to the oxygen-containing gas supply passage 46 a, in the stacking direction. Thus, it is possible to reduce the thickness of the unit cells 12 a, 12 b in the stacking direction while maintaining the sufficient flow field height and the sufficient seal height in the first oxygen-containing gas supply connection channel 78 a and the second oxygen-containing gas supply connection channel 78 c. Accordingly, reduction in the entire size of the fuel cell 10 is achieved easily, and in particular, the size of the fuel cell stack mounted in a vehicle is suitably reduced.

FIG. 15 is a partial cross sectional view showing a fuel cell 80 according to a second embodiment of the present invention. The constituent elements that are identical to those of the fuel cell 10 according to the first embodiment are labeled with the same reference numerals, and detailed description thereof will be omitted. Also in third to sixteenth embodiments as described later, the constituent elements that are identical to those of the fuel cell 10 according to the first embodiment are labeled with the same reference numerals, and detailed description thereof will be omitted.

The fuel cell 80 is formed by stacking unit cells 82 a, 82 b alternately in the direction indicated by the arrow A. The unit cell 82 a is formed by sandwiching a first membrane electrode assembly 20 a between a first metal separator 83 and a second metal separator 84. The unit cell 82 b is formed by sandwiching a second membrane electrode assembly 20 b between a third metal separator 86 and a fourth metal separator 88.

The outer dimensions of the first metal separator 83 are larger than the outer dimensions of the second metal separator 84. The first metal separator 83 has an inner seal (second seal member, third seal) 90 a for preventing leakage of the coolant, an intermediate seal (first seal member, first seal) 90 b provided outside the inner seal 90 a for preventing leakage of the fuel gas, and an outer seal (third seal member, second seal) 90 c provided outside the intermediate seal 90 b for preventing leakage of the oxygen-containing gas.

The outer dimensions of the third metal separator 86 are larger than the outer dimensions of the fourth metal separator 88. The third metal separator 86 has an inner seal (second seal member) 92 a for preventing leakage of the coolant, an intermediate seal (first seal member) 92 b provided outside the inner seal 92 a for preventing leakage of the fuel gas, and an outer seal (third seal member) 92 c provided outside the intermediate seal 92 b for preventing leakage of the oxygen-containing gas.

In effect, the first metal separator 83 is used as the third metal separator 86 by 180° rotation such that the first metal separator 83 and the third metal separator 86 are oriented oppositely. In effect, the second metal separator 84 is used as the fourth metal separator 88 by 180° rotation such that the second metal separator 84 and the fourth metal separator 88 are oriented oppositely.

The inner seals 90 a, 92 a contact the outer ends of the fourth metal separator 88 and the second metal separator 84, respectively. The intermediate seals 90 b, 92 b contact the outer end of the solid polymer electrolyte membrane 30 b of the second membrane electrode assembly 20 b and the outer end of the solid polymer electrolyte membrane 30 a of the first membrane electrode assembly 20 a, respectively. The outer seals 90 c, 92 c contact the outer ends of third metal separator 86 and the first metal separator 83 which are adjacent to each other.

In the second embodiment having the above structure, in the unit cell 82 a, the inner seal 90 a, the intermediate seal 90 b, and the outer seal 90 c are formed integrally on only one surface of the first metal separator 83. Thus, seal forming process is significantly simplified, and carried out economically. Further, as the fuel gas seal structure, dual seal structure including the intermediate seal 90 b and the outer seal 90 c is adopted. Thus, the same advantages as in the case of the first embodiment are obtained. For example, the performance of preventing the leakage of the fuel gas is improved suitably.

FIG. 16 is a partial cross sectional view showing a fuel cell 80 a according to a third embodiment of the present invention. The constituent elements that are identical to those of the fuel cell 80 according to the second embodiment are labeled with the same reference numerals, and detailed description thereof will be omitted.

The fuel cell 80 a is formed by stacking unit cells 82 a, 82 b alternately in the direction indicated by the arrow A. The unit cell 82 a is formed by sandwiching a first membrane electrode assembly 20 a between a first metal separator 83 a and a second metal separator 84 a. The unit cell 82 b is formed by sandwiching a second membrane electrode assembly 20 b between a third metal separator 86 a and a fourth metal separator 88 a.

The outer dimensions of the first metal separator 83 a are smaller than the outer dimensions of the second metal separator 84 a. A seal member 90 is formed integrally with the second metal separator 84 a. The seal member 90 includes an inner seal 90 a for preventing leakage of the coolant, an intermediate seal 90 b provided outside the inner seal 90 a for preventing leakage of the fuel gas, and an outer seal 90 c provided outside the intermediate seal 90 b for preventing leakage of the oxygen-containing gas.

The outer dimensions of the third metal separator 86 a are smaller than the outer dimensions of the fourth metal separator 88 a. A seal member 92 is formed integrally with the fourth metal separator 88 a. The seal member 92 includes an inner seal 92 a for preventing leakage of the coolant, an intermediate seal 92 b provided outside the inner seal 92 a for preventing leakage of the fuel gas, and an outer seal 92 c provided outside the intermediate seal 92 b for preventing leakage of the oxygen-containing gas.

In effect, the second metal separator 84 a is used as the fourth metal separator 88 a by 180° rotation such that the second metal separator 84 a and the fourth metal separator 88 a are oriented oppositely. In effect, the first metal separator 83 a is used as the third metal separator 86 a by 180° rotation such that the first metal separator 83 a and the third metal separator 86 a are oriented oppositely.

The inner seals 90 a, 92 a contact the outer ends of the third metal separator 86 a and the first metal separator 83 a, respectively. The intermediate seals 90 b, 92 b contact the outer end of the solid polymer electrolyte membrane 30 b of the second membrane electrode assembly 20 b and the outer end of the solid polymer electrolyte membrane 30 a of the first membrane electrode assembly 20 a, respectively. The outer seals 90 c, 92 c contact the outer ends of fourth metal separator 88 a and the second metal separator 84 a which are adjacent to each other.

In the third embodiment, operation of forming the seal member is not required for the first metal separator 83 a and the third metal separator 86 a. Thus, the seal forming process is significantly simplified, and carried out economically. The overall production cost of the fuel cell 80 a is reduced easily.

Further, in the third embodiment, the seal member 90 includes the inner seal 90 a for preventing leakage of the coolant, the intermediate seal 90 b for preventing leakage of the fuel gas, and the outer seal 90 c for preventing leakage of the oxygen-containing gas. The inner seal member 90 a, the intermediate seal 90 b, and the outer seal 90 c are offset from one another in the stacking direction. Likewise, the seal member 92 includes the inner seal 92 a for preventing leakage of the coolant, the intermediate seal 92 b for sealing the fuel gas, and the outer seal 92 c for preventing leakage of the oxygen-containing gas. The inner seal 92 a, the intermediate seal 92 b, and the outer seal 92 c are offset from one another in the stacking direction.

In the structure, it is possible to prevent leakage of the coolant, the fuel gas, and the oxygen-containing gas, and reduce the overall size of the fuel cell 80 a while maintaining the sufficient seal height in each fluid channel.

FIG. 17 is a cross sectional view showing a fuel cell 100 according to a fourth embodiment of the present invention.

The fuel cell 100 is formed by stacking a plurality of unit cells 102 in the direction indicated by the arrow A. Each of the unit cells 102 is formed by sandwiching the membrane electrode assembly (electrolyte electrode assembly) 104 between a first metal separator 106 and a second metal separator 108 (see FIGS. 17 and 18). The membrane electrode assembly 104 includes a solid polymer electrolyte membrane 30, a cathode 32, and an anode 34. The outer dimensions (surface areas) of the solid polymer electrolyte membrane 30, the cathode 32, and the anode 34 are the same.

The outer dimensions of the first metal separator 106 are smaller than the outer dimensions of the second metal separator 108. In effect, the first metal separator 106 has the same structure as the first metal separator 22 of the first embodiment.

A seal member 110 is formed integrally with the second metal separator 108. As shown in FIGS. 17 and 19, on the surface 24 a, the seal member 110 includes a first seal (inner seal) 110 a formed around the first fuel gas flow field 52, and a second seal (outer seal) 110 b.

The first seal 110 a contacts the outer end of the membrane electrode assembly 104, and the second seal 110 b contacts the second metal separator 108 of the adjacent unit cell 102 (see FIG. 17).

In the fourth embodiment having the above structure, instead of adopting the first membrane electrode assembly 20 a and the second membrane electrode assembly 20 b including the electrodes having different sizes (referred to as a stepped MEA) according to the first embodiment, the membrane electrode assembly 104 including the electrodes having the same size is adopted. Also in the structure, the same advantages as in the case of the first embodiment are obtained.

FIG. 20 is a cross sectional view showing a fuel cell 112 according to a fifth embodiment of the present invention.

The fuel cell 112 is formed by stacking a plurality of unit cells 114 in a direction indicated by the arrow A. The unit cell 114 includes a membrane electrode assembly 104, a first metal separator 106, and a second metal separator 116. The outer dimensions of the first metal separator 106 are smaller than the outer dimensions of the second metal separator 116.

A first seal member 118 is formed integrally on the surface 24 a of the second metal separator 116, around the fuel gas flow field 52. The first seal member 118 includes a first seal (inner seal) 118 a and a second seal (outer seal) 118 b. The first seal 118 a contacts the outer end of the membrane electrode assembly 104. The second seal 118 b contacts a second seal member 119 (described later) provided on the second metal separator 126 of the adjacent unit cell 122.

The second seal member 119 is formed integrally with the surface 24 b of the second metal separator 126 around the coolant flow field 54. The second seal member 119 includes a seal 119 a. The outer ends of the membrane electrode assembly 104 and the first metal separator 106 are sandwiched between the seal 119 a and the inner seal 118 a.

In the fuel cell 120 having the above structure, the same advantages as in the cases of the first to fourth embodiments are obtained.

FIG. 21 is a cross sectional view showing a fuel cell 120 according to a sixth embodiment of the present invention.

The fuel cell 120 is formed by stacking a plurality of unit cells 122 in a direction indicated by the arrow A. The unit cell 122 includes a membrane electrode assembly 104, a first metal separator 124, and a second metal separator 126. The outer dimensions of the first metal separator 124 are smaller than the outer dimensions of the second metal separator 126.

As shown in FIGS. 22 and 23, at substantially central positions of both ends of the first metal separator 124 in the longitudinal direction indicated by the arrow B, extensions 128 a, 128 b protrude toward the coolant supply passage 48 a and the coolant discharge passage 48 b of the second metal separator 126, respectively.

The first metal separator 124 has a plurality of grooves 132 a, 132 b on a surface 22 a.

The inlet side and the outlet side of the oxygen-containing gas flow field 40 are opened to the outside through the grooves 132 a, 132 b. As shown in FIG. 23, a curved seal member 134 is provided around the oxygen-containing gas flow field 40 on the surface 22 a of the first metal separator 124. Part of the seal member 134 forms the grooves 132 a, 132 b.

As shown in FIG. 24, a coolant flow field 54 is formed in the surface 22 b of the first metal separator 124. The extensions 128 a, 128 b have grooves 136 a, 136 b connecting the coolant flow field 54 to the coolant supply passage 48 a and the coolant discharge passage 48 b extending through the second metal separator 126.

As shown in FIG. 25, a first seal member 138 and a second seal member 140 are formed integrally on the surface 24 a of the second metal separator 126 around the fuel gas flow field 52.

The membrane electrode assembly 104 is sandwiched between the first seal member 138 and the seal member 134 of the first metal separator 124. The second seal member 140 contacts the second metal separator 126 of the adjacent unit cell 122 (see FIG. 21).

As shown in FIG. 25, the first seal member 138 seals the oxygen-containing gas supply passage 46 a, the oxygen-containing gas discharge passage 46 b, the coolant supply passage 48 a, and the coolant discharge passage 48 b, while allowing the fuel gas supply passage 50 a and the fuel gas discharge passage 50 b to be connected to the fuel gas flow field 52.

Grooves 142 a are formed by the first seal member 138 between the fuel gas supply passage 50 a and the fuel gas flow field 52, and grooves 142 b are formed by the first seal member 138 between the fuel gas discharge passage 50 b and the fuel gas flow field 52.

As shown in FIG. 25, channels 143 a, 143 b connecting the fuel gas supply passage 50 a and the fuel gas discharge passage 50 b to the fuel gas flow field 52 are formed in the second metal separator 126. The channels 143 a, 143 b include grooves 142 a, 142 b, respectively.

Grooves 144 a and 144 b are formed between the first seal member 138 and the second seal member 140. The grooves 144 a connect the oxygen-containing gas supply passage 46 a to the grooves 132 a of the first metal separator 124, and the grooves 144 b connect the oxygen-containing gas discharge passage 46 b to the grooves 132 b.

As shown in FIGS. 23 and 25, the second metal separator 126 has channels 146 a, 146 b connecting the oxygen-containing gas supply passage 46 a and the oxygen-containing gas discharge passage 46 b respectively to the oxygen-containing gas flow field 40 of the first metal separator 124. The channels 146 a, 146 b include grooves 144 a, 144 b. The grooves 132 a, 132 b are connected to the oxygen-containing gas flow field 40 through the grooves 144 a, 144 b.

In the fuel cell 120 having the above structure, the first seal member 138 and the second seal member 140 of one of the adjacent second metal separators 126 tightly contact the other of the adjacent second metal separators 126.

In the structure, the oxygen-containing gas supplied to the oxygen-containing gas supply passage 46 a of each unit cell 122 flows into the channel 146 a (see FIG. 25), and then, the oxygen-containing gas is supplied from the grooves 144 a of the second metal separator 126 to the oxygen-containing gas flow field 40 through the grooves 132 a of the first metal separator 124 (see FIG. 23). The fuel gas consumed in the reaction in the oxygen-containing gas flow field 40 is discharged to the channel 146 b from the grooves 132 b, and flows through the grooves 144 b to the oxygen-containing gas discharge passage 46 b.

As shown in FIG. 25, the fuel gas supplied to the fuel gas supply passage 50 a of the unit cells 122 flows into the channel 143 a, and the fuel gas is supplied to the fuel gas flow field 52 through the grooves 142 a. The fuel gas consumed in the fuel gas flow field 52 is discharged from the grooves 142 b of the channel 143 b to the fuel gas discharge passage 50 b.

Further, the coolant supplied to the coolant supply passage 48 a flows through the grooves 136 a in the extension 128 a of the first metal separator 24, and the coolant is supplied to the coolant flow field 54 (see FIG. 24). Then, the coolant used for cooling each unit cell 122 is discharged to the coolant discharge passage 48 b through the grooves 136 b formed in the other extension 128 b.

In the sixth embodiment having the above structure, the same advantages as in the cases of the first to fifth embodiments are obtained. For example, the outer dimensions of the first metal separator 124 are reduced significantly. It is possible to reduce the weight and the size of each of the unit cells 122.

FIG. 26 is a cross sectional view showing a fuel cell 150 according to a seventh embodiment of the present invention.

The fuel cell 150 is obtained by modifying the fuel cell 120 according to the sixth embodiment by adopting so called skip cooling structure in which the coolant flow field 54 is provided for every predetermined number of, e.g., every two membrane electrode assemblies 104.

The fuel cell 150 is formed by stacking a first metal separator 124, a membrane electrode assembly 104, a second metal separator 152, another membrane electrode assembly 104, a third metal separator (having the same structure as the second metal separator 126) 154, another first metal separator 124, another membrane electrode assembly 104, another second metal separator 152, another membrane electrode assembly 104, and another third metal separator 154 successively in the direction indicated by the arrow A.

A fuel gas flow field 52 is formed on one surface of the second metal separator 152 facing the membrane electrode assembly 104, and the membrane electrode assembly 104 is sandwiched between the second metal separator 152 and the first metal separator 124. An oxygen-containing gas flow field 40 is formed on the other surface of the second metal separator 152 facing the other membrane electrode assembly 104, and the other membrane electrode assembly 104 is sandwiched between the second metal separator 152 and the third metal separator 154.

In the seventh embodiment, the area of the coolant flow field 54 is effectively reduced (by half). Thus, the overall dimension of the fuel cell 150 in the stacking direction is reduced significantly.

FIG. 27 is a cross sectional view showing a fuel cell 160 according to an eighth embodiment of the present invention.

The fuel cell 160 is formed by stacking unit cells 162 in the direction indicated by the arrow A. Each of the unit cells 162 is formed by sandwiching the membrane electrode assembly 104 between a first carbon separator 164 and a second carbon separator 166.

The fuel cell 160 has substantially the same structure as the fuel cell 120 according to the sixth embodiment. The outer dimensions of the first carbon separator 164 are smaller than the outer dimensions of the second carbon separator 166. A seal member 168 corresponding to the seal member 134 is provided on the first carbon separator 164. A first seal 170 and a second seal 172 corresponding to the first seal member 138 and the second seal member 140 are provided on the second carbon separator 166. The first seal 170 and the second seal 172 are attached to the second carbon separator 166 after molding.

In the eighth embodiment having the above structure, the same advantages as in the cases of the first to seventh embodiments are obtained. For example, the dimensions of the first carbon separator 164 are reduced as much as possible. It is possible to reduce the overall weight and size of the fuel cell 160.

The fuel cell 160 according to the eighth embodiment has substantially the same structure as the fuel cell 120 according to the sixth embodiment, and adopts the first carbon separator 164 and the second carbon separator 166. Also in the first to fifth embodiments and the seventh embodiments, carbon separators may be adopted.

FIG. 28 is an exploded perspective view showing a fuel cell 200 according to a ninth embodiment of the present invention.

The fuel cell 200 is formed by stacking unit cells 202 a, 202 b alternately in the direction indicated by the arrow A. The unit cell 202 a is formed by sandwiching a first membrane electrode assembly 204 a between the first metal separator 22 and the second metal separator 24, and the unit cell 202 b is formed by sandwiching a second membrane electrode assembly 204 b between the third metal separator 26 and the fourth metal separator 28.

The first membrane electrode assembly 204 a has a substantially quadrangular shape as a whole. At opposite ends of the first membrane electrode assembly 204 a in the direction indicated by the arrow B, first uneven portions 206 a forming the first channel 76 a are provided in the same plane as the electrode surface. The first uneven portion 206 a at one end of the first membrane electrode assembly 204 a in the direction indicated by the arrow B includes a first extension 37 a, a first cutout 39 a, a second extension 37 b, and a second cutout 39 b from upper to lower positions. Further, the first uneven portion 206 a at the other end of the first membrane electrode assembly 20 a in the direction indicated by the arrow B includes a third extension 37 c, a third cutout 39 c, a fourth extension 37 d, and a fourth cutout 39 d from upper to lower positions.

The second membrane electrode assembly 204 b has the same structure as the first membrane electrode assembly 204 a. At opposite ends of the second membrane electrode assembly 204 b in the direction indicated by the arrow B, a second uneven portions 206 b forming the second channel 76 b are provided in the same plane as the electrode surface. The second uneven portion 206 b at one end of the second membrane electrode assembly 204 b in the direction indicated by the arrow B includes a fifth cutout 39 e, a fifth extension 37 e, a sixth cutout 39 f, and a sixth extension 37 f from upper to lower positions. Further, the second uneven portion 206 b at the other end of the second membrane electrode assembly 204 b in the direction indicated by the arrow B includes a seventh cutout 39 g, a seventh extension 37 g, an eighth cutout 39 h, and an eighth extension 37 h from upper to lower positions.

In the ninth embodiment having the above structure, the first uneven portions 206 a and the second uneven portions 206 b are offset from each other in the stacking direction, and the same advantages as in the cases of the above embodiments are obtained.

FIG. 29 is an exploded perspective view showing a fuel cell 210 according to a tenth embodiment of the present invention.

The fuel cell 210 is formed by stacking unit cells 212 a, 212 b alternately in the direction indicated by the arrow A. The unit cell 212 a is formed by sandwiching a first membrane electrode assembly 214 a between the first metal separator 22 and the second metal separator 24, and the unit cell 212 b is formed by sandwiching a second membrane electrode assembly 214 b between the third metal separator 26 and the fourth metal separator 28.

The first membrane electrode assembly 214 a has a substantially quadrangular shape as a whole. At opposite ends of the first membrane electrode assembly 214 a in the direction indicated by the arrow B, first uneven portions 216 a forming the first channel 76 a are provided in the same plane as the electrode surface. The first uneven portion 216 a at one end of the first membrane electrode assembly 104 a in the direction indicated by the arrow B includes a first cutout 218 a, a first extension 220 a, and a second cutout 218 b from upper to lower positions. Further, the first uneven portion 216 a at the other end of the first membrane electrode assembly 214 a in the direction indicated by the arrow B includes a second extension 220 b and a third cutout 218 c from upper to lower positions.

The second membrane electrode assembly 214 b has the same structure as the first membrane electrode assembly 214 a. At opposite ends of the second membrane electrode assembly 214 b in the direction indicated by the arrow B, second uneven portions 216 b forming the second channel 76 b are provided in the same plane as the electrode surface. The second uneven portion 216 b at one end of the second membrane electrode assembly 214 b in the direction indicated by the arrow B includes a fourth cutout 218 d and a third extension 220 c from upper to lower positions. The second uneven portion 216 b at the other end of the second membrane electrode assembly 214 in the direction indicated by the arrow B includes a fifth cutout 218 e, a fourth extension 220 d, and a sixth cutout 218 f from upper to lower positions.

A first oxygen-containing gas supply connection channel 78 a is formed at the first cutout 218 a between the first metal separator 22 and the second metal separator 24. A first fuel gas supply connection channel 79 a is formed between the first extension 220 a and the second metal separator 24. A first oxygen-containing gas discharge connection channel 78 b is formed at the third cutout 218 c between the first metal separator 22 and the second metal separator 24. A first fuel gas discharge connection channel 79 b is formed between the first extension 220 a and the second metal separator 24.

A second oxygen-containing gas supply connection channel 78 c is formed at the fourth cutout 218 d between the third metal separator 26 and the fourth separator 28. A second fuel gas supply connection channel 79 c is formed between the fourth extension 220 d and the fourth metal separator 28. A second oxygen-containing gas discharge connection channel 78 d is formed at the sixth cutout 218 f between the third metal separator 26 and the fourth metal separator 28. A second fuel gas discharge connection channel 79 d is formed between the third extension 220 c and the fourth metal separator 28.

In the tenth embodiment having the above structure, the first uneven portions 216 a and the second uneven portions 216 b are offset from each other in the stacking direction, and the same advantages as in the cases of the above embodiments are obtained.

FIG. 30 is an exploded perspective view showing a fuel cell 230 according to an eleventh embodiment of the present invention.

The fuel cell 230 is formed by stacking unit cells 232 a, 232 b alternately in the direction indicated by the arrow A. The unit cell 232 a is formed by sandwiching a first membrane electrode assembly 234 a between a first metal separator 236 and a second metal separator 238, and the unit cell 232 b is formed by sandwiching a second membrane electrode assembly 214 b between a third metal separator 240 and a fourth metal separator 242.

The first membrane electrode assembly 234 a has a substantially quadrangular shape as a whole. At opposite ends of the first membrane electrode assembly 234 a in the direction indicated by the arrow B, first uneven portions 236 a forming the first channel 76 a are provided in the same plane as the electrode surface. The first uneven portions 236 a include a first extension 37 a, a first cutout 39 a, a second extension 37 b, a second cutout 39 b, a third extension 37 c, a third cutout 39 c, a fourth extension 37 d and a fourth cutout 39 d provided at opposite ends of the first membrane electrode assembly 234 a in the direction indicated by the arrow B.

The second membrane electrode assembly 234 b has the same structure as the first membrane electrode assembly 234 a. At opposite ends of the second membrane electrode assembly 234 b in the direction indicated by the arrow B, a second uneven portion 236 b forming the second channel 76 b is provided along the electrode surface. The second uneven portion 236 b includes a fifth cutout 39 e, a fifth extension 37 e, a sixth cutout 39 f, and a sixth extension 37 f, a seventh cutout 39 g, a seventh extension 37 g, an eighth cutout 39 h, and an eighth extension 37 h. The first extension 37 a to the eighth extension 37 h, and the first cutout 39 a to the eighth cutout 39 h are inclined in a predetermined direction from the vertical direction.

The shapes of the first metal separator 236 to the fourth metal separator 242 correspond to the shapes of the first membrane electrode assembly 234 a and the second membrane electrode assembly 234 b. Likewise, the shapes of the oxygen-containing gas supply passage 46 a, the coolant supply passage 48 a, the fuel gas discharge passage 50 b, the fuel gas supply passage 50 a, the coolant discharge passage 48 b, and the oxygen-containing gas discharge passage 46 b correspond to the shapes of the first membrane electrode assembly 234 a and the second membrane electrode assembly 234 b.

In the eleventh embodiment having the above structure, the first uneven portion 236 a and the second uneven portion 236 b are offset from each other in the stacking direction, and the same advantages as in the cases of the above described embodiments are obtained.

FIG. 31 is a cross sectional view showing a fuel cell 300 according to a twelfth embodiment of the present invention.

The fuel cell 300 is formed by stacking a plurality of unit cell 302 in the direction indicated by the arrow A. The unit cell 302 is formed by sandwiching the membrane electrode assembly (electrolyte electrode assembly) 304 between a first metal separator 306 and a second metal separator 308 (see FIGS. 31 and 32). The membrane electrode assembly 304 includes a solid polymer electrolyte membrane 30, a cathode 32, and an anode 34. The outer dimensions (surface areas) of the solid polymer electrolyte membrane 30, the cathode 32, and the anode 34 are the same.

The outer dimensions of the first metal separator 306 are smaller than the outer dimensions of the second metal separator 308. In effect, the first metal separator 306 has the same structure as the first metal separator 22 of the first embodiment.

A seal member 310 is formed integrally with the second metal separator 308. As shown in FIGS. 31 and 33, on the surface 24 a, the seal member 310 includes a first seal 310 a, a second seal 310 b, and a third seal 310 c formed around the first fuel gas flow field 52.

The first seal 310 a for preventing leakage of the fuel gas contacts the outer end of the solid polymer electrolyte membrane 30, the second seal 310 b for preventing leakage of the oxygen-containing gas contacts the outer end of the first metal separator 306, and the third seal 310 c for preventing leakage of the coolant contacts the second metal separator 308 of the adjacent unit cell 302 (see FIG. 31).

In the twelfth embodiment having the above structure, instead of adopting the first membrane electrode assembly 20 a and the second membrane electrode assembly 20 b including the electrodes having different sizes (referred to as a stepped MEA) according to the first embodiment, the membrane electrode assembly 304 including the electrodes having the same size as the solid polymer electrolyte membrane is adopted. Also in the structure, the same advantages as in the case of the above described embodiments are obtained.

FIG. 34 is a cross sectional view showing a fuel cell 320 according to a thirteenth embodiment of the present invention.

The fuel cell 320 is formed by stacking a plurality of unit cells 322 in a direction indicated by the arrow A. The unit cell 322 includes a membrane electrode assembly 304, a first metal separator 324, and a second metal separator 326. The outer dimensions of the first metal separator 324 are substantially the same as the outer dimensions of the second metal separator 326.

As shown in FIGS. 35 to 37, an oxygen-containing gas supply passage 46 a, a coolant supply passage 48 a, a fuel gas discharge passage 50 b, a fuel gas supply passage 50 a, a coolant discharge passage 48 b, and an oxygen-containing gas discharge passage 46 b extend through the first metal separator 324 and the second metal separator 326 in the stacking direction indicated by the arrow A.

As shown in FIGS. 34 and 36, an outer seal (third seal) 328 is formed integrally on a surface 22 b of the first metal separator 324 around the coolant flow field 44, along the outer end of the surface 22 b.

As shown in FIG. 37, a seal member 330 is formed integrally on a surface 24 a of the second metal separator 326 around the fuel gas flow field 52. The seal member 330 includes an inner seal (first seal) 330 a and an intermediate seal (second seal) 330 b. The inner seal 330 a contacts the outer end of the membrane electrode assembly 304 (see FIG. 34). The intermediate seal 330 b contacts outer end of the first metal separator 324 such that the membrane electrode assembly 304 is sandwiched between the intermediate seal 330 b and the first metal separator 324.

As shown in FIG. 37, the seal member 330 seals the oxygen-containing gas supply passage 46 a, the oxygen-containing gas discharge passage 46 b, the coolant supply passage 48 a, and the coolant discharge passage 48 b while allowing the fuel gas supply passage 50 a and the fuel gas discharge passage 50 b to be connected to the fuel gas flow field 52.

Grooves 342 a are formed by the seal member 330 between the fuel gas supply passage 50 a and the fuel gas flow field 52, and grooves 342 b are formed by the seal member 330 between the fuel gas discharge passage 50 b and the fuel gas flow field 52. Grooves 344 a are formed near the oxygen-containing gas supply passage 46 a, and grooves 344 b are formed near the oxygen-containing gas discharge passage 46 b.

In the fuel cell 320 having the above structure, the oxygen-containing gas supplied to the oxygen-containing gas supply passage 46 a of each unit cell 322 flows through the grooves 344 a of the second metal separator 326 (see FIG. 37), and the oxygen-containing gas is supplied to the oxygen-containing gas flow field 40 of the first metal separator 324 (see FIG. 35). The oxygen-containing gas consumed in the reaction in the oxygen-containing gas flow field 40 flows through the grooves 344 b of the second metal separator 326, and the oxygen-containing gas is discharged to the oxygen-containing gas discharge passage 46 b.

As shown in FIG. 37, the fuel gas supplied to the fuel gas supply passage 50 a of each unit cell 322 flows through the grooves 342 a, and the fuel gas is supplied to the fuel gas flow field 52. The fuel gas consumed in the fuel gas flow field 52 is discharged to the fuel gas discharge passage 50 b through the grooves 342 b.

The coolant supplied to the coolant supply passage 48 a is supplied to the coolant flow field 54 (see FIG. 36). After the coolant is used for cooling each unit cell 322, the coolant is discharged to the coolant discharge passage 48 b.

In the thirteenth embodiment, the outer seal 328 for preventing leakage of the coolant is provided in the outer end of the first metal separator 324, and the inner seal 330 a for preventing leakage of the fuel gas, and the intermediate seal 330 b for preventing leakage of the oxygen-containing gas are provided in the second metal separator 326. The outer seal 328, the inner seal 330 a, and the intermediate seal 330 b are offset from one another in the stacking direction. Thus, the same advantages as in the cases of the above described embodiments are obtained. For example, the dimension of the fuel cell 320 in the stacking direction is reduced as much as possible, and the overall size of the fuel cell 320 is reduced easily.

FIG. 38 is a cross sectional view showing a fuel cell 350 according to a fourteenth embodiment of the present invention.

The fuel cell 350 includes a plurality of unit cells 352. Each of the unit cells 352 is formed by stacking a membrane electrode assembly 304 between a first metal separator 354 and a second metal separator 356.

As shown FIG. 39, the seal member 358 is formed integrally on the surface 22 a of the first metal separator 354 around the oxygen-containing gas flow field 40. The seal member 358 includes an inner seal (second seal) 358 a and an intermediate seal (first seal) 358 b. The inner seal 358 a contacts the outer end of the cathode 32 of the membrane electrode assembly 304. The intermediate seal 358 b is formed around the membrane electrode assembly 304, and contacts the second metal separator 356 (see FIG. 38).

An outer seal (third seal) 360 is formed integrally on the surface 24 b of the second metal separator 356 around the coolant flow field 54, around the outer end of the surface 24 b.

In the fourteenth embodiment, the inner seal 358 a for preventing leakage of the oxygen-containing gas, the intermediate seal 358 b for preventing leakage of the fuel gas, and the outer seal 360 for preventing leakage of the coolant are offset from one another in the stacking direction. Thus, the same advantages as in the cases of the above described embodiments are obtained.

FIG. 40 is a cross sectional view showing a fuel cell 370 according to a fifteenth embodiment of the present invention.

The fuel cell 370 includes unit cells 372 each including a membrane electrode assembly 374, a first metal separator 324, and a second metal separator 326. As shown in FIGS. 40 and 41, the membrane electrode assembly 374 includes an anode 34 c having a surface area smaller than the surface areas of the solid polymer electrolyte membrane 30 and the cathode 32.

In the fifteenth embodiment having the above structure, the same advantages as in the case of the fuel cell 320 according to the thirteenth embodiment are obtained.

FIG. 42 is a cross sectional view showing a fuel cell 380 according to a sixteenth embodiment of the present invention.

The fuel cell 380 includes unit cells 382 each formed by sandwiching a membrane electrode assembly 304 between the first metal separator 306 and the second metal separator 384 (see FIGS. 42 and 43). A seal member 330 having an inner seal 330 a and an intermediate seal 330 b is formed integrally on the surface 24 a of the second metal separator 384. An outer seal (third seal) 386 is formed integrally on the surface 24 b of the second metal separator 384. The outer seal (third seal) 386 contacts the surface 24 a of the adjacent second metal separator 384 to prevent leakage of the coolant (see FIG. 42).

In the sixteenth embodiment having the above structure, the inner seal 330 a, the intermediate seal 330 b, and the outer seal 386 are offset from one another in the stacking direction, and the same advantages as in the cases of the above described embodiments are obtained.

FIG. 44 is a cross sectional view showing a fuel cell 390 according to a seventeenth embodiment of the present invention.

The fuel cell 390 includes unit cells 392 each having a membrane electrode assembly 304, a first carbon separator 394, and a second carbon separator 396. A first seal 398 as an inner seal member and a second seal 400 as an intermediate seal member are formed on the surface 24 a of the second carbon separator 396. The first seal 398 contacts the outer end of the membrane electrode assembly 304 for preventing leakage of the fuel gas, and the second seal 400 contacts the first carbon separator 394 such that the membrane electrode assembly 304 is sandwiched between the second seal 400 and the first carbon separator 394 for preventing leakage of the oxygen-containing gas.

A third seal 402 for preventing leakage of the coolant is formed on the surface 24 b of the second carbon separator 396. The third seal 402 contacts the outer end of the first carbon separator 394 of the adjacent unit cell 392 for preventing leakage of the coolant.

The first seal 398, the second seal 400, and the third seal 402 are offset from one another in the stacking direction, and the same advantages as in the cases of the above described embodiments are obtained. For example, the overall dimension of the fuel cell 390 in the stacking direction is reduced as much as possible. 

1. A fuel cell comprising stacked unit cells each including an electrolyte electrode assembly and a first separator and a second separator sandwiching the electrolyte electrode assembly, the electrolyte electrode assembly including an anode, a cathode, and an electrolyte interposed between the anode and the cathode, a fuel gas flow field for supplying a fuel gas along the anode and an oxygen-containing gas flow field for supplying an oxygen-containing gas along the cathode being formed in the unit cells, a coolant flow field for supplying a coolant along an electrode surface being formed between the unit cells at intervals of every predetermined number of the unit cells, wherein at least the first separator or the second separator includes a first seal for preventing leakage of the fuel gas, a second seal for preventing leakage of the oxygen-containing gas, and a third seal for preventing leakage of the coolant; and the first seal, the second seal, and the third seal, are offset from one another in a stacking direction.
 2. A fuel cell according to claim 1, wherein the first seal forms an inner seal, the second seal forms an intermediate seal, and the third seal forms an outer seal.
 3. A fuel cell according to claim 1, wherein the third seal forms an inner seal, the first seal forms an intermediate seal, and the second seal member forms an outer seal.
 4. A fuel cell according to claim 1, wherein the second seal forms an inner seal, the first seal forms an intermediate seal, and the third seal member forms an outer seal.
 5. A fuel cell according to claim 1, wherein a fuel gas supply passage, a fuel gas discharge passage, an oxygen-containing gas supply passage, an oxygen-containing gas discharge passage, a coolant supply passage, and a coolant discharge passage extend through an outer end of at least one of the first separator and the second separator in the stacking direction. 